ESAB | Mig C342 3ph Origo™ | Service manual | ESAB Mig C342 3ph Origo™ User manual

ESAB Mig C342 3ph Origo™ User manual
Origo™
Mig C342 3 ph
Service manual
0349 300 085
20120725
Valid for serial no. 804-xxx-xxxx
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP2 Digital instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP2:1 Calibration and voltage correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP2:2 Connections to the digital instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mig C342 3ph, 400-415V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1 Control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1AP1:1
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:2 2-stroke / 4-stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:3 Start / Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:4 Current relay, Creep start / Normal start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:5 Motor driving / braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:6 Tachometer input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:7 Burn-back time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:8 Wire feed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:9 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1:10 Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP1 - Mig C342 3ph component positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is ESD? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal switch (thermostat) replacement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rights reserved to alter specifications without notice.
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READ THIS FIRST
Maintenance and repair work should be performed by an experienced person, and
electrical work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault-tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit
board is divided into numbered blocks, which are described individually in more detail in
the description of operation. All component names in the wiring diagram are listed in the
component description.
This manual contains details of design changes that have been made up to and including
April 2008.
The Mig 342 3 ph is designed and tested in accordance with international and
European standards IEC/EN 60974-1 and 60974-10.
On completion of service or repair work, it is the responsibility of the person(s)
performing the work to ensure that the product still complies with the requirements of
the above standard.
CAUTION
Read and understand the instruction manual before
installing or operating.
INTRODUCTION
The Mig C342 3ph is step controlled switched power source in a compact design,
intended for welding with solid steel, stainless steel or aluminum wire as well as
tubular wire with or without shielding gas.
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TECHNICAL DATA
Mig C342 3ph
Voltage
230/380-415V, 3∼50Hz
230/440V, 3∼60Hz
Permissible load at
100% duty cycle
195 A/24 V
60 % duty cycle
250 A/27 V
30 % duty cycle
340 A/31 V
Setting range (DC)
40A/16V-340A/31V
Open circuit voltage
16-40 V
Open circuit power
240 W
Efficiency
77%
Power factor
0.95
Control voltage
42 V, 50/60 Hz
Wire feed speed
1,9 - 20m/min
Burnback time
0 - 0,5s
Creep start
OFF / ON
2/4 stroke
2/4
Welding gun connection
EURO
Dimensions lxwxh
840x425x830
Weight
120 kg
Operating temperature
-10 to +40oC
Enclosure class
IP 23
Application classification
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at
a certain load without overloading. The duty cycle is valid for 40° C.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
Application class
The symbol
indicates that the power source is designed for use in areas with increased
electrical hazard.
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AP2 Digital instrument
AP2:1 Calibration and voltage correction
The meter has a possibility of the voltage and current calibration, as well
as a possibility of the current-dependant voltage correction, to show a
voltage approximately equal to the actual arc voltage.
Since all meters are factory calibrated it is recommended to carry out a
second calibration only if it's needed. In most applications a zero voltage
correction (no correction) is factory adjusted.
For the calibration an accurate reference meter and a resistance load
are required. The resistance load should force at least 100A current flow.
For calibration following actions should be done:
1
Switch the machine on and load it. The meter should indicate voltage
and current presence.
2
Press simultaneously both pushbuttons placed on the meter PC board.
In sequence, symbols of the calibration modes appear: ”U” - voltage
calibration, ”I” - current calibration, ”dU” - voltage correction. Release the
buttons as the required mode appears.
3
Adjust the voltage or the current value equal to the value shown by the
reference meter by means of the pushbuttons: S1 - ”+”, S2 - ”-”.
Voltage calibration mode
The reference meter should be connected to the same potentials as a
calibrated meter. Exclusively in this mode a voltage without correction is
shown on display.
Voltage correction mode
The reference meter should be connected to the end of mass cable and
to the torch current tip, which are connected to the external load. In this
mode, as well as during the regular work, the meter shows a voltage
taking in account voltage drops on cables and welding torch. An
adjustment of the voltage correction should be carried out only in
assumption of the proper voltage calibration and in the presence of load
current above 100A.
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AP2:2 Connections to the digital instrument
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WIRING DIAGRAM
Component description
CAUTION
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
Observe precautions for handling electrostaticsensitive devices.
S
Use proper static-proof bags and boxes.
This component description refers to the wiring diagram:
AP1
Circuit board
AP2
Digital instrument, accessory
C1, C2, C3, CES
Capacitor 0,1uF/250V
EV1
Fan
FU1 - FU5
Fuse
G1
Tachogenerator, incorporated in motor M01
HL1
Lamp, white, On/Off
KM1
Contactor 42V, 50-60Hz
L1
Inductor
M1
Feed unit motor rated voltage 24V
QF1
Switch, ON/OFF
R1
Resistor
R2
Varistor
RES
Resistor
RP1
Potentiometer, wire feed speed
RP2
Potentiometer, burn-back time
RS1
Shunt, accessory
SA1
4-step switch, coarse selection of welding voltage
SA2
10-step switch, fine selection of welding voltage
S1
Switch, creep start ON/OFF
S2
Switch, 2/4-stroke
ST1
Thermal overload cutout, opens at 120oC. Mounted at the cooling fins
of the diode bridge.
ST2
Thermal overload cutout, opens at 130oC. Mounted at the winding of
transformer TM1.
TC1
Control transformer
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TC2
Transformer for CO2 heater, accessory
TC3
Transformer for digital instrument, accessory
TM1
Main transformer
V1-V6
Diode bridge
V7
Led yellow indication, thermal overload
XP
Connector
XS1, XS2
Main welding current contact, single - pole
XT2
9 - pole terminal block
YV1
Gas valve
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Mig C342 3ph, 400-415V
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DESCRIPTION OF OPERATION
The processor on the control board incorporates EPROM memory that machine
program is stored in. The processor monitors the wire feed speed. If the speed
deviates from the set value more than 1.5m/min for more than five seconds, wire
feed will be stopped.
AP1 Control board
1AP1:1
Power supply
42V AC supplies welding gun trigger switch, the gas valve and the main
contactor. In addition, 42V is available on contacts H01 and H02.
Rectifier BR1 rectifies the 42V AC to 60V DC. Capacitor C28 smoothens
the voltage, which then supplies the wire feeder motor. Motor current
consumption at maximum load is 3,5A.
Transistor Q8 is a pre-regulator which reduces the voltage from 60V to
20V. Q8 is current-limited down to about 200mA. If the 20V supply drops
below 13V, the wire feeder stops.
VR1 and VR2 are 5V and 15V voltage regulators respectively.
AP1:2 2-stroke / 4-stroke
2-stroke
When S2 is open, the unit operates in 2-stroke mode. Operating the
trigger on the welding gun starts the motor, opens the gas valve and
energises the power unit contactor.
Releasing the trigger stops the motor, de-energises the contactor and
closes the gas valve. If burn-back is active, welding ceases when the
burn-back time has elapsed.
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4-stroke
When S2 is closed, the unit operates in 4-stroke mode. Operating the
trigger on the welding gun opens the gas valve: releasing the trigger
then starts the motor and energises the power unit contactor.
Operating the trigger switch for a second time stops the motor and
de-energises the contactor in the power unit: releasing the switch then
closes the gas valve.
If burn-back is in operation, welding ceases when the burn-back time has
elapsed.
AP1:3 Start / Stop
The welding gun switch is supplied with 42V AC. Closing the switch
activates optocoupler IC1, causing the voltage across C35 to go low.
AP1:4 Current relay, Creep start / Normal start
The current relay is activated when the welding current exceeds 20A.
Creep start means that the motor runs at 1.9m/min until the current relay
operates, after which the speed increases to the set speed. If the current
relay does not operate within one second after starting, the motor speed
increases to the set speed in any case.
Selector switch S1 selects Creep Start On/Off. Closing the switch on to
the 0V rail disables creep start.
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AP1:5 Motor driving / braking
Driving
The motor is powered from the smoothed +60V supply. Motor speed is
controlled by pulse width modulation of transistor Q1. The pulse
frequency is 12kHz, and the maximum on-time is 97% of the pulse cycle
time. During the pulse off-time, the motor current freewheels through
diode D8.
At 24V motor supply voltage, the wire feed rollers speed is 160r/min. A
wire feed speed of 20m/min is equall to roller speed of 212 r/min.
Resistor R19 produces a voltage drop proportional to the motor current.
If the current exceeds 7A, IC5:2 turns off the gate pulses to Q1. When
the current falls, Q1 conducts again at the next gate pulse.
Braking
When the motor starts, capacitor C43 charges up via diode D28: the
voltage is limited to 15V by zener diodes D10 and D21. When the motor
is to brake, the LED in optocoupler IC8 lights, causing the transistor in
IC8 to conduct and discharge capacitor C43 (15V) to the gate of
transistor Q3. The transistor conducts thus short-circuits the motor
voltage through resistors R51 and R64, that limit the current down to
about 20 A.
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AP1:6 Tachometer input
Tachometer G1 is fitted in the motor casing. Tachometer output
frequency is 796Hz for a wire feed speed of 20m/min. Comparator IC4:2
converts the sine wave signal from the tachometer to a square wave at
the same frequency.
AP1:7 Burn-back time
The burn-back time is the time from when motor braking starts until the
main contactor in the power unit opens. It can be adjusted between 0
and 0.5s with potentiometer RP2.
AP1:8 Wire feed speed
The wire feed speed range is from 1.9 to 20m/min. A 5V reference
voltage signal at connection A02 represents a speed of 20m/min.
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AP1:9 Gas valve
The gas valve is connected to board contacts G04 and G05.
The valve is energised via triac TC1.
AP1:10 Contactor
The start signal for power unit is connected to board contact G03.
The contactor is energised via triac TC102.
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AP1 - Mig C342 3ph component positions
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SERVICE INSTRUCTIONS
CAUTION
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
Observe precautions for handling electrostaticsensitive devices.
S
Use proper static-proof bags and boxes.
What is ESD?
A sudden transfer or discharge of static electricity from one object to another. ESD
stands for Electrostatic Discharge.
How does ESD damage occur?
ESD can cause damage to sensitive electrical components, but is not dangerous to
people. ESD damage occurs when an ungrounded person or object with a static
charge comes into contact with a component or assembly that is grounded. A rapid
discharge can occur, causing damage. This damage can take the form of immediate
failure, but it is more likely that system performance will be affected and the
component will fail prematurely.
How do we prevent ESD damage?
ESD damage can be prevented by awareness. If static electricity is prevented from
building up on you or on anything at your work station, then there cannot be any
static discharges. Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics)
generate and hold static charge, so you should not bring unnecessary nonconductive
items into the work area.
It is obviously difficult to avoid all such items, so various means are used to drain off
any static discharge from persons to prevent the risk of ESD damage. This is done
by simple devices: wrist straps, connected to ground, and conductive shoes.
Work surfaces, carts and containers must be conductive and grounded. Use only
antistatic packaging materials. Overall, handling of ESD-sensitive devices should be
minimized to prevent damage.
Thermal switch (thermostat) replacement procedure
1. Spare thermostat must be the same type as replaced one.
2. Spare thermostat should be mounted within radius of 10mm or less from broken
thermostat. If it's possible and safe for transformer winding, broken thermostat
may be removed. Then the spare thermostat is to be mounted right in place of
broken one.
3. Spare thermostat should adjoin protected winding as tight as possible.
4. Spare thermostat must be secured with silicone glue of working temperature of
200oC or higher.
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NOTES
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NOTES
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